JP2004164635A - Monitoring device for production management - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To efficiently carry out production management such as specification of a product number of a product with a machining defect from multiple products. <P>SOLUTION: This monitoring device for production management is constructed so that a position sensor 10 detecting positional data of a ram, a pressure sensor 11 detecting pressurization data, a temperature sensor 12 detecting temperature data of a die, and a die displacement sensor 13 detecting displacement of the die are attached to a machining device 1. From the start to the end of molding in a single molding process, the monitoring device collects data from the respective sensors 10-13 at every sampling time and stores them. Retrieval data are stored in a RAM of a data collector 2, and all the data including the retrieval data are stored in a data recording storage device 25 from a hard disk. In retrieval, the retrieval data stored in the RAM 24 is used for retrieval, and necessary data are fetched from the data recording storage device 25. <P>COPYRIGHT: (C)2004,JPO

Description

  The present invention relates to a production management monitor device. More specifically, it monitors the operating status of machines that repeatedly process a large number of products at a relatively high speed, such as plastic processing machines that have a pressing force, such as press machines, and searches and sorts out defective products that can be obtained. The present invention relates to a monitor device used for production management such as detection and control of operation failure in a molding process.

  Conventionally, the same product has been produced at high speed and in large quantities in machine molding and press machines. However, defective products may be mixed in such mass produced products, and they are good or bad. It is necessary to sort out good products. In some cases, the occurrence of these defective products can be eliminated by adjusting the machine. In such a case, it is desired to detect the defective product early and control the machine in a good state.

  On the other hand, detecting the state of a machine and displaying it in a waveform or the like has been conventionally performed for the purpose of analyzing a production process or the like. For this purpose, waveform display software has conventionally been marketed, and there is an example in which it is used for collecting tri-data of a hydraulic press. However, in this method, the machine is operated for one cycle, and the data is displayed in a waveform on a personal computer. In addition, devices with built-in waveform display software with a data logger (a function of storing a certain amount of data) are also sold, and can store data to some extent continuously, but the memory capacity is not enough for actual production. .

  In addition, when viewing measurement data with waveform display software, it is necessary to verify the data on a personal computer in order, one trial at a time. It cannot be used for actual production management purposes, such as identifying product groups and processing steps that may be possible.

  The present invention specifies the product number of a product having a processing defect from a large number of products in an actual production process, specifies the state of a machine or a molding process that may cause a processing defect, and determines the quality of the product. Another object of the present invention is to provide a production management monitor device that can efficiently perform production management, such as performing feedback control on the state of a machine based on a detection result.

  A monitor device for production management according to the present invention (claim 1) is a device used for production control of a machine that mass-produces the same product, and monitors a change in the state of the machine when the machine manufactures one product. Means for detecting as a series of numerical values, means for generating a specific numerical value from the numerical value as search data, and associating the obtained search data with a code specifying a manufactured product or a molding process. Storage means; search means for searching the search data for data that matches the input specific condition; output means for outputting a product or molding process code corresponding to the data searched by the search means And characterized in that:

  Such a production management monitor device preferably includes a second storage means for storing all or a main part of the series of numerical values in association with a product or a code of a molding process. ). In this case, it is preferable that the second storage means be a randomly accessible storage device having a storage capacity of 100 megabytes or more, particularly 1 gigabyte or more (claim 3). In particular, a hard disk is used as the storage device. Is preferable (claim 4). Other storage means include an MO, a flash memory, a DVD, a DAT, and a flexible disk.

  A production management monitor device further comprising a display unit for displaying, as a waveform image, detection data corresponding to a specified product among the codes of the product or the molding process output by the output unit. More preferred. The machine may be another machine, but in the case of a press machine, the detected state includes the ram pressing force, the ram position, the temperature of the ram guide, the mold displacement. One or more states selected from the group consisting of: mold temperature, die cushion generating ability, knockout generating ability, frame displacement, die cushion position, knockout position, lubricating oil temperature, and main motor current value. (Claim 6). In the case of a hydraulic press, pump discharge pressure, oil temperature, pump drive motor current value, etc., in addition to the above-mentioned states, can be mentioned. Further, in the case of a multi-axis press, in addition to the above-mentioned state, the pressing force and position of each axis are included.

  Further, the series of detected numerical values is compared with a numerical value sequence serving as a criterion for determining whether a product or a molding process is acceptable, and when a predetermined difference is determined, an alarm to the mass-production machine and / or a control output of the machine is provided. It is preferable to have an output means (claim 7). Further, it is preferable that the device for inputting the search condition and the search means are connected by communication so that the search can be performed from a remote place.

  When the detection data is obtained, the production management monitor device of the present invention creates and stores search data at the same time. At the time of search, the search is performed based on the search data. For this reason, the number of data to be searched for is not limited to all data but only search data for search, so that the number of data to be searched can be reduced. Further, compared with the total number of detected data, the search data has a smaller number of data, so that a product to be searched can be specified in a short time. As a result, it is possible to efficiently perform production management, for example, by specifying a product number or a molding process of a product having a processing defect from a large number of products.

  In the case where the monitor device includes a second storage unit that stores all or a main part of the series of numerical values in association with a product or a code of a molding process (claim 2), the monitor is specified by a search. For a product or a molding process, all or a major part of a series of numerical sequences can be retrieved from the second storage means. Therefore, it is possible to analyze the cause of the defective product and the defective molding process in detail and take measures to prevent the defective product from occurring. Such measures can be taken in real time, after work has been completed, or at a later date to respond to customer complaints.

  In the case where the second storage means is a random access storage device having a storage capacity of 100 megabytes or more (claim 3), the waveform data which requires a huge amount of data even if the product is large in volume. In this case, the detection data can be efficiently stored, and the storage can be easily taken out. When a hard disk is employed as such a storage device (claim 4), the configuration can be made compact and the storage capacity can be increased. In this case, when the search data is accessed, access to the RAM is performed. When access to all data is access to the hard disk, the amount of all data that can be stored is large, and the access at the time of search is fast. .

  In the production management monitor device (claim 5), further comprising display means for displaying, as a waveform image, detection data corresponding to a specified product among codes of the product or the molding process output by the output means. With the pattern described above, the manufacturing state can be intuitively confirmed or understood.

  The machine is a press machine, and the state includes a ram pressing force, a ram position, a ram guide portion temperature, a mold displacement amount, a mold temperature, a die cushion generating ability, a knockout generating ability, and a frame. In the case of one or more states selected from the group consisting of the displacement amount of the die, the die cushion position, the knockout position, the lubricating oil temperature, and the main motor current value (claim 6), each time the pressing force of the product by the press is applied. Etc. can be saved. For example, search data is created under the condition of the maximum value of the pressing force in one process, and a search is made for a defective product or a defective molding process by searching a large number of data for those having a maximum pressing force greater than a specific value. The determination can be made immediately.

  The series of detected numerical values is compared with a numerical value sequence serving as a criterion for determining whether a product or a molding process is acceptable. If a predetermined difference is determined, an alarm is output to the mass-produced machine and / or output as a machine control output. In the case where there is a means (claim 7), the user can be notified in real time of the occurrence of a defective product or a defective molding process by an alarm or can be notified of the tendency of occurrence. In the case of a hydraulic press machine, etc., the occurrence of subsequent defective products or defective molding steps should be suppressed or prevented by feedback control, such as immediately raising or lowering the hydraulic pressure or adjusting the pressing force. Can be.

  In a monitor device (Claim 8) in which the device for inputting the search condition and the search means are connected by communication so that the search can be performed from a remote place, even if the factory is far from the management department, the monitor device can be easily remote-controlled. More efficient production management can be performed by specifying and searching for a target item from the ground and performing waveform analysis.

  Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. FIG. 1 is a configuration diagram showing an entire production system using a monitor device of the present invention, FIG. 2 is a block diagram of a hardware function showing an embodiment of a data collection device in the monitor device of the present invention, and FIG. FIG. 4 is a block diagram of a software function of the collection device, FIG. 4 is a flowchart for performing control based on an alarm value according to the present invention, FIG. 5 is a block diagram of a software function showing one embodiment of a search-side personal computer in the monitor device, 6a and 6b are flowcharts when collecting and storing various data by the monitor device, FIG. 7 is an explanatory diagram showing a storage state when data is stored by the monitor device, and FIGS. 8 and 9 are monitor diagrams of the monitor device. Serial No. in the device 10 and 11 are flowcharts showing a method of creating search data from measured data under specific conditions, and FIGS. 12 to 14 are flowcharts of performing a search from a personal computer. FIG. 15 is an explanatory view showing the relationship between the maximum pressurization value and the maximum value time obtained by the apparatus of the present invention.

  The production system shown in FIG. 1 includes a processing device 1 to be managed by a monitor device such as a hydraulic press or a mechanical press, such as various molding machines, and pressurization data and temperature data of a mold during operation of the processing device 1. Data collection device 2 for collecting and storing various data such as ram slide position data, mold displacement data, and the like, and a data group collected and stored by the data collection device 2 via an Ethernet (registered trademark) hub 3 And a general personal computer 4 for searching for desired items and displaying waveforms. Although the monitor device of the present invention can be constituted only by the data collection device 2, in this embodiment, the data collection device 2 and the personal computer 4 are combined. The data collection device 2 is preferably of a stand-alone type, so that it can accommodate both new and existing equipment. In particular, in many cases, the customer already has the personal computer 4 for production management, and in that case, the personal computer can be used as the personal computer 4 of the monitor device. Further, in this embodiment, the data collection device 2 is accessed via the Internet from a personal computer 4 located at a remote place via a modem 5 and a communication line 6 such as a telephone line, a dedicated line, an optical communication line, and searched. Or a waveform display.

  In this system, the data collection device 2 automatically saves the pressing force during operation of the processing device 1 and the slide position data of the ram every predetermined sampling time. During or after the machine operation, data searched under specific conditions is checked on the screen of the personal computer 4 as waveforms, and the waveform data is converted into numerical values for each sampling time (so-called spreadsheet software or spreadsheet software). The data can be analyzed using a csv format text file that can be read in Excel. Of course, analysis may be performed with other spreadsheet software. It can also be used for analyzing the machine operation of a try machine, and the measured data for each shot is displayed in a waveform by manual operation so that it can be used for analysis of molding.

  The processing apparatus 1 shown in FIG. 1 shows a case of a hydraulic press. This processing apparatus 1 has a position sensor 10 composed of a linear scale that detects the upper and lower positions of a ram, and detects a pressing force in a hydraulic pipe. A pressure sensor 11, a temperature sensor 12 composed of a thermocouple for detecting the temperature of the mold, and a mold displacement sensor 13 for detecting displacement of the mold are arranged. Further, the case where the read data is processed to generate a new physical unit includes, for example, the case where the position data is read and differentiated to generate velocity data, and further differentiated to generate acceleration data. As shown in FIG. 2, the processing apparatus 1 includes a molding start button 14 for starting the molding operation of the processing apparatus 1, and a limit switch driven by the ram that is raised after the ram is lowered and the product is pressed. 15 are provided. The molding start button 14 is pressed by an operator to give a start signal to the processing apparatus 1 to the data collection apparatus 2, and the molding end signal (stop signal) when the limit switch 15 is driven. ) Is sent to the data collection device 2. Similarly, the sensors 10 to 13 also send detection signals to the data collection device 2. In the case of a machine that performs molding when the molding button is pressed (ON) and ends molding when the hand is released (OFF), the OFF signal can be used as a processing end signal. As will be described later, when the data collection device generates a measurement start signal or a measurement end signal, a signal from a molding start button or a signal from a limit switch is unnecessary.

  FIG. 2 shows a block diagram of the data collection device 2. The molding start button 14 and the limit switch 15 from the processing device 1 side, the I / O interface 20 for receiving a digital signal from the position sensor 10, and the pressure on the processing device 1 side An A / D converter 21 for receiving analog signals from the sensor 11, the temperature sensor 12, and the mold displacement sensor 13, a CPU 22 for overall control, a ROM 23, search data to be described later, and the above-described sensors 10 to 13 A data recording and storage device 25 comprising a RAM 24 for temporarily storing data from the RAM 24 for each sampling, a hard disk for sequentially storing a molding data file and a search file from the data in the RAM 24 after molding is completed, and a personal computer shown in FIG. 4 and a communication interface 26 for performing communication. The capacity of the data recording and storage device 25 is at least 100 megabytes, preferably 1 gigabyte, and more preferably 30 gigabytes (GB) or more. An alarm 27 and a processing device (machine) 1 are connected to the I / O interface 20. When the data collection device 2 detects or determines occurrence of a defective product or the like, an alarm output is transmitted and an alarm is issued. The machine 27 can be blown, and the operation of the processing apparatus 1 can be controlled. The control of the processing device (mechanical control) includes an emergency stop and the like. However, it is not necessary to use an alarm signal or a machine control signal, and in such a case, these connections are unnecessary.

  FIG. 3 is a block diagram of the CPU 22 which performs control in accordance with the procedure of a program, in which the internal configuration of the CPU 22 is functionally blocked. That is, the physical unit value conversion unit 30, the data value comparison unit 31, the molding data file creation unit 32, the ram speed calculation unit 33, the counter unit 34, the alarm value comparison unit 29, the date / time and clock unit 35 , A search unit 36, a waveform data readout unit 37, a molding time calculation unit 38, and a search file creation unit 39, which mainly constitute the CPU 22.

  The physical unit value converter 30 converts digital data values from various sensors such as the position sensor 10, the pressure sensor 11, the temperature sensor 12, and the mold displacement sensor 13 into physical units such as mm, Pascal, ° C, and kN (load). The data value comparing section 31 compares various data values input at each sampling time to find the maximum value and the minimum value. The molding data file creation unit 32 stores the measured data for each file name or for the serial number of the product. Each is stored in the work area of the RAM 24 and the data recording and storage device 25 of the hard disk as a folder or a file in a hierarchical structure format. The ram speed calculation unit 33 calculates the speed of the ram from the position from the position sensor 10 for each sampling, and calculates the maximum speed and the minimum speed of the ram in the calculation area of the CPU and the RAM 24. Is stored in the data recording storage device 25. The counter section 34 stores the serial number of the product to be processed. The date / time section 35 adds time data every time measurement data is stored by the internal clock function.

  As shown in the flowchart of FIG. 4, the alarm value comparison unit 29 compares the measured values from the various sensors with a preset range (alarm setting range), and the measured value deviates from a predetermined range. Sometimes, a signal such as "generation of defective product" is issued. Then, based on the signal, an alarm (27 in FIG. 2) is blown to call attention of the operator. Alternatively, a control signal of the processing device (reference numeral 1 in FIGS. 1 and 2) is transmitted to control the machine to stop or change the state. As a result, waveform data and the like can be used for real-time operation and control of the machine in addition to analyzing the cause of the defective product after the fact. However, when it is not necessary, the alarm output and the machine control output in real time need not be adopted.

  The search unit 36 is a database server for searching for a predetermined item stored in the RAM 24 in response to a search request from the personal computer 4, and is linked with the web server so as to send the search result to the personal computer 4. The waveform data reading unit 37 reads a series of data groups required by the search result from the personal computer 4 from the data recording / storing device 25 and sends the data group to the personal computer 4. The processing molding time is calculated from the start signal from the molding start button 14 and the molding end signal from the limit switch 15 shown in FIG. 2, and is stored in the RAM 24 or the data recording storage device 25. The search file creator 39 creates a search file based on the physical unit data temporarily recorded in the RAM. The search file is stored in the RAM in the work area of the database and in the hard disk in the storage area.

  The flowchart shown in FIG. 4 shows a flow of an alarm output process by the alarm value comparison unit 29 in FIG. In this process, first, the channel counter is set to 0 in step S61, and in step S62, the number of all channels is compared with the channel counter to determine whether or not the channel counter is larger. If so, the process is stopped, and if smaller, the value converted into the physical unit system is read for each channel in step S63 (current value). Then, in step S64, the alarm value and the alarm direction determined for each channel are compared with the current value to determine whether the current value is outside the range or within the range. If it is out of the range, the corresponding alarm output is output in step S65, and the corresponding alarm information is stored in the alarm information file in step S66. After that, the value of the channel counter is increased by one in step S67.

  FIG. 5 shows a block diagram of the personal computer 4. The control unit 40 includes a CPU, an operation input unit 45 including a keyboard and a mouse, a RAM 46, a display unit 47 including a liquid crystal display device such as a CRT or a TFT, and a product. A storage unit 48 for storing an arbitrary data group for processing, a communication interface 49 for exchanging data and signals with the data recording and storage device 25, and the like. The control unit 40 includes a search control unit 41 that performs a control to receive a search request and a search result of a desired item, and a data transfer control unit 42 that performs a control to receive a data transfer request and a data group to be obtained from the search result. A waveform display control unit 43 for displaying received data as a waveform, a data format conversion unit 44 for converting waveform data into Excel data, and a file for setting a file name of a file for saving data, and the like. It comprises a name setting unit 50 and an alarm setting unit 51 for setting and storing a numerical value (alarm value) in a range to be alarmed by the above-mentioned alarm value comparison unit (reference numeral 29 in FIG. 3). When the alarm output or the machine control output is not required, the alarm setting unit is unnecessary.

  In the file name setting section 50, the file name of the file to be saved and the serial number of the molding data (product) can be set on the screen. Note that it is preferable to save and register the file name in the form of “file name + serial number” with the same name (file name) for a series of processing and a serial number for distinguishing each file. (See FIG. 7). The serial number for the file name at that time is automatically assigned. These data are also used at the time of database registration (see FIGS. 8 and 9). The serial number of the molding data increases by one for each molding data. The alarm setting unit 51 is capable of setting a set value and an alarm direction of each channel on a screen. The alarm direction sets whether an alarm is output when an alarm value is exceeded or an alarm is output when an alarm value is under. The alarm value set here is used by the set value comparison unit 29 in FIG. 3 and sends out the alarm signal and the machine control signal in FIG. 2 according to the flow in FIG. As the alarm value, the maximum value, the minimum value, the average value in one cycle or a predetermined cycle of the physical quantity such as the pressing force, the mold displacement, and the temperature, or the above-described physical quantity at the predetermined ram position in one cycle, Various values can be employed.

  Next, an operation in the case where the member to be molded is molded by the processing apparatus 1 to measure and store various data, and an operation such as a search after storing the measurement data and waveform data will be described. FIG. 6A shows a flow in the case of acquiring data in one process of the member to be molded. First, as shown in step S1, when the operator presses the molding start button 14, molding is started in the processing device 1. Based on the signal of the molding start button 14 or when a measurement start signal is input from the press machine, a start signal is input to the data collection device 2 or measurement is performed based on the molding start timing created on the data collection device side. Is started, and the interruption process of FIG. 6B for measuring various data at predetermined sampling times is permitted. This allows the subroutine to run autonomously independently of the main routine. In this embodiment, the sampling time for data measurement in this interrupt processing can be set to, for example, 10 msec, but an arbitrary sampling time between 1 msec and 1 sec can be set.

  In this interrupt processing, the digital value of A / D and I / O, that is, the input from various sensors is read in step S201 when the sampling time arrives, and is determined for each channel (each sensor output) in step S202. To the specified physical unit system. Next, in step S203, detection processing of the maximum value / minimum value of each channel is performed as described later. Next, in step S203a, a process of comparing with an alarm value determined for each channel and outputting an alarm is performed. Next, in step 203b, a process of comparing with a machine control value determined for each channel and outputting a machine control is performed. Next, in step S204, the sampling count value and the physical quantity data are temporarily recorded in the RAM 24 sequentially connected to the CPU 22. Then, in step S205, it is confirmed whether or not a molding end signal has been received. If not, the interrupt processing for each sampling time is continued. Thereby, during one molding process, data from each channel (sensor) is sequentially stored in the RAM 24 at each sampling time. If the alarm output and the machine control output are not performed, steps 203a and 203b are omitted.

  The molding end signal is a signal from the limit switch 15 that detects the rise of the ram of the press, as described above, and the molding end signal is input to the CPU 22. However, a molding end signal can be sent out only when the molding start button 14 is pressed without transmitting a molding end signal by the limit switch, and the molding end signal can be set as the molding signal OFF. As described above, the start / end of the molding signal includes the case where the measurement start / end signal is output from the machine side and the case where the molding start / end timing is determined on the data collection device side. When the molding is completed and the CPU 22 has received the termination signal, an interruption termination process is performed. The data collection from each channel for each sampling time is performed by interrupt processing as described above in order to make the sampling time accurate. Data from each channel includes time data, pressurization data from the pressure sensor 11, ram position data from the position sensor 10, temperature data from the temperature sensor 12, mold displacement data from the mold displacement sensor 13, and the like. is there.

  In the main routine of FIG. 6A, when the measurement is started, it is determined in step S3 whether or not a molding end signal is received. If so, the interruptable state is terminated in step S4. Next, in step S5, the sampling count value at the end is taken in as the molding time, and each sampling count value temporarily recorded in the RAM 24 and the physical unit data for each channel is temporarily stored as a file in the hard disk 25 with a fixed file name. I do. This is the so-called all data, which is a database for drawing the later formed waveform.

  In step S6, a new search data file is created. That is, items required at the time of retrieval, such as automatically set file name, date, and product serial number. , The molding time, the maximum value and the minimum value of each channel, and the molding start time, are stored in the data recording and storage device 25 of the hard disk. In steps S5 and S6, data set by the file name setting unit (see reference numeral 50 in FIG. 5) is used. Next, as shown in step S7, the search data is read and stored in the RAM 24 of the work area of the database and the data recording and storage device 25 of the hard disk in the storage area. At this time, save the file temporarily with a fixed file name. This step S7 is shown in detail in FIG. Here, the reason why the search data is stored in the RAM 24 is that the access speed is high at the time of the search and the response time for the search and the like is short. Note that the storage in the RAM 24 in step S5 is a RAM area managed by the interrupt processing program, and the search data managed by the database program is stored in a format different from this. The saving is to be saved at a different address in a different format from the above-described temporary saving for multitask processing. The reason why the search data is stored on the hard disk is to protect data when the power is turned off. When the above steps are completed, the data processing for one molding process is completed. It should be noted that the values captured in each of the above channels may not only be stored but also used as alarms or machine control as predetermined processing values (calculated values).

  The operation shown in FIG. 6A shows the measurement and storage of various data associated with the molding of one molded member, and FIG. 7 shows the RAM 24 in the work area of the database and the hard disk in the storage area. The items searched from the search keyword from the personal computer 4 are stored in the RAM 24 of the data collection device 2 as a "search data area", and all the data for each sampling is a huge amount, and is constituted by a hard disk. The data is stored in the data recording storage device 25.

  The data stored in the RAM 24 includes a file name, date data, and a serial number of a product to be molded. 1, 2, 3, ..., for each file name, molding time data, molding time data, pressurization maximum value, maximum value time when pressing force becomes maximum from the start of molding, pressurization minimum value, The minimum value time, the maximum temperature of the mold, the minimum temperature, the maximum ram speed, the minimum ram speed, the maximum displacement, the minimum displacement, etc., when the pressure becomes minimum from the start of molding. In this embodiment, the position sensor 10, the pressure sensor 11, the temperature sensor 12, and the mold displacement sensor 13 are used as an example. However, if there is another item to be measured, a sensor is separately arranged and an arbitrary sensor is arranged. Data can be acquired and saved. The file name is a file name with a serial number (file name + serial number). Usually, the next serial number is automatically assigned each time a new file is created. The data related to the above-mentioned molding is not only stored but may be used as a predetermined processing value (calculated value) for an alarm or machine control.

  In the data recording and storage device 25, all data is stored at each sampling time, and items to be stored in the RAM 24 are also stored in the data recording and storage device 25 at the same time. As shown in FIG. 7, the data recording / storing device 25 is used as a "data area for waveform display". The data section, the ram position data section, the temperature data section, and the mold displacement data section are provided.

  In the data collection device 2, the serial number of the product is set for each molding. And the serial number. Is automatically given. The data collection device 2 measures and manages from day to second by the date / time / clock unit 35. In the case of FIG. 8, when the date is changed, as shown in step S11, the counter unit 34 of the CPU 22 of the data collection device 2 changes the date. The value of the counter is reset to “zero” (see step S12). Then, as shown in step S13, when the molding start button 14 is pressed to perform molding and an ON signal is input, or when a molding start signal is issued by other means, as shown in step S14, The value of the counter of the counter section 34 is increased by one. In this case, the value of the counter of the counter section 34 becomes “1”, and the serial No. Is stored as "1" (see step S15). Thereafter, each time the molding process is performed on the molded member, the serial number of the product is changed. Automatically increases by one and the serial number is automatically increased. And the serial No. The data is saved.

  When the process is performed according to the flow of FIG. 8, when the date is changed, the serial number of the product becomes “zero”. In such processing, it is necessary to change the file name when the date changes. Therefore, as shown in FIG. 9, if the date and time at which the waveform was created are automatically read out and set in the search data file, there is no risk of accidental overwriting. In the process of FIG. 9, first, at step 71, the file name and the serial number are read from the file for setting the file name. Then, in step S72, the date (including time) when the waveform data file was created is read out and set in the search data file. Then, in step S73, a file name + serial number and a molding serial number are set in the search data file. Further, in step S74, the search data file is registered as a new item in the database. Then, in step S75, the file name temporarily given to the molding data is given a file name + serial number + extension (.add) and stored in another location. Further, in step S76, the content of the search data file is stored in another location with a file name + serial number + extension (.csv). Further, in step S77, the molding data and the search data file temporarily stored are deleted. Next, the value of the serial number for the file name and the serial number of the product are incremented by one (step S78), and finally the file name and the serial number are stored in the setting file (step S79).

  In step S4 shown in FIG. 6A, the pressurization data, the ram position data, the temperature data, and the mold displacement data are measured and stored for each sampling time together with the time data, but the pressurization data is measured. The case where the maximum pressurized value and the minimum pressurized value are measured and stored will be described.

  FIG. 10 shows a flowchart for measuring and storing the maximum pressure value. First, as shown in step S21, an initial value "0 (minimum value)" is set in the maximum pressure value area. Then, in step S22, the time data at the time of sampling and the pressurization data from the pressure sensor 11 are fetched, and the digital data converted by the A / D converter 21 is converted into a physical unit value by the physical unit value converter 30 of the CPU 22 ( See step S23). Next, the process proceeds to step S24, where the data value comparing unit 31 compares whether or not the pressure data is larger than the previously stored pressure data. The process proceeds to step S26 to determine the presence or absence of the molding end signal without rewriting the time data and the pressure data.

  If it is determined in step S24 that the pressure data is larger than the previously stored pressure data, the process proceeds to step S25, in which the current pressure data is rewritten and the time data is also stored. The above operation is repeated for each sampling until a molding end signal is input, and the maximum pressurization value is measured. In step S26, when a molding end signal is input from the limit switch 15, this operation ends. The measurement of the maximum value time when the pressure reaches the maximum value from the start of the measurement is calculated by the molding time calculation unit 38 and stored in the RAM 24 and the data recording and storage device 25.

  Next, a case where the minimum pressure value is measured and stored will be described with reference to FIG. First, as shown in step S31, the maximum pressure value area is set to, for example, a maximum value 65535 (assuming an area of 16 bits). The value 65535 of the numerical value here means the maximum positive value of the 16-bit variable. Then, in step S32, the time data at the time of sampling and the pressure data from the pressure sensor 11 are fetched, and the digital data converted by the A / D converter 21 is converted into a physical unit value by the physical unit value converter 30 of the CPU 22. (See step S33). Next, the process proceeds to step S34, where the data value comparing unit 34 compares whether or not the pressure data is smaller than the previously stored pressure data. The process proceeds to step 36 for judging the presence or absence of a molding signal without rewriting the data and the pressurization data.

  If it is determined in step S34 that the pressure data is smaller than the previously stored pressure data, the process proceeds to step S35, where the current pressure data is rewritten and the time data is also stored. Then, the above operation is repeated for each sampling until the molding end signal is input, and the minimum pressurization value is measured. In step S36, when the molding end signal is input from the limit switch 15, this operation ends. The measurement of the minimum value time when the pressure becomes the minimum value from the start of the measurement is calculated by the molding time calculation unit 38 and stored in the RAM 24 and the data recording storage device 25.

  The maximum speed, minimum speed, maximum temperature, minimum temperature of the ram, the maximum and minimum displacement of the mold, and the method of storing and storing are basically the same as when measuring and storing the maximum pressurized value and the minimum pressurized value. The description is omitted because it is the same.

  Next, the operation when the personal computer 4 searches for the data collection device 2 from the personal computer 4 will be described with reference to FIGS. First, as shown in step S41 of FIG. 12, the browser software installed in the personal computer 4 is started, and search conditions are input from the screen of the personal computer 4 (the display unit 47 shown in FIG. 5) (see step S43). . Next, the process proceeds to step S43, where a search button displayed on the screen is clicked to send a search request signal to the data collection device 2. This control operation is performed by the search control unit 41 of the control unit 40 shown in FIG. Then, the search request signal is sent from the communication interface 49 of the personal computer 4 to the communication interface 26 shown in FIG.

  Although a specific example of the search item will be described later, in step S44, the data stored in the RAM 24 is searched by the search unit 36 of the CPU 22 of the data collection device 2 according to the search condition sent from the personal computer 4. Then, the search result is sent to the personal computer 4, where the search control unit 41 displays the search result on the display unit 47 (see step S45). Next, as shown in step S46 shown in FIG. 12, the target file name is clicked, and a data transfer request signal is transmitted to cause the data collection device 2 to transfer all the data related thereto. This control operation is performed by the data transfer control unit 42 of the control unit 40.

  In the data collection device 2, all the data is read out by the waveform data reading unit 37 of the CPU 22 in accordance with the data transfer request from the personal computer 4 (see step S <b> 47), and the data is transferred to the personal computer 4. Then, as shown in step S48, when a waveform data file is created by the waveform display control unit 43 of the control unit 40 and the waveform data is displayed on the display unit 47, continuous waveform data with the horizontal axis as time is displayed. It is displayed on the display unit 47 by the waveform display software (see steps S49 and S50).

  The data of the search result on the personal computer 4 side and all data transferred from the data collection device 2 based on the search result can be stored in the storage unit 48.

  Next, as shown in step S51 of FIG. 13, when there are a plurality of target files in the search result and a waveform of another file name is displayed, the process returns to step S46, and the process returns to step S46. If no waveform is displayed, the process moves to step S52. In step S53, if the waveform data is to be converted into Excel data (spreadsheet software data, spreadsheet data), the process proceeds to step S53, where the application installed in the data format conversion unit 44 is activated to convert the data into Excel data. I do. Then, as shown in step S54, the waveform data is converted into Excel data, whereby various data for each sampling are displayed in a list continuously as numerical values.

  As described above, a search can be performed from the personal computer 4 to the data collection device 2, and a search example is as follows. The date can be specified in the range of year, month, day, hour, minute and second. For example, the date can be specified in the time zone in which the processing apparatus 1 is operated. For example, when 9:00 to 10:00 is specified, the data measured in that time zone is read. When you save it to a specified file, you can check it with waveform display software. In the file name, if the file name is specified before the operation of the processing apparatus 1, (for example, if the system is specified as the N system), the serial number for each molding is displayed under the file name of the N system 1, the N system 2, and the like. . Is given, the file name and the assigned serial number. Search can be performed within the range. In addition, the serial No. Of course is also possible. For example, serial No. of continuous molding. 10 to 20 or individual serial No. When specifying No. 12 and 15, the serial No. of those moldings Is read out, and thereafter it can be confirmed by the waveform data in the same manner as described above.

  Furthermore, a search can be performed based on the molding time from the start of measurement to the end of measurement, and this is effective for searching when the molding time exceeds a predetermined time due to some problem, such as in the case of press working. In addition, a search can be performed within the range of the maximum value of the pressing force from the start of the measurement. For example, when the pressing force is 100 kN, if the pressure is specified from 98 kN to 100 kN, the corresponding file can be retrieved and retrieved. Similarly, the search can be performed even in the range of the minimum value. In the case of a press machine, when the product accuracy changes due to the variation of the bottom dead center, setting of the position data makes this search effective.

  Further, as shown in FIG. 15, the search can be performed also from the time from the start of the measurement at which the maximum pressurization value is generated, and when the generation of the maximum pressurization value is, for example, 3 sec, the range is 2.8 to 3.2 sec. Can be specified to search for the corresponding file (measurement data). Similarly, the search can be performed in the range of the time when the minimum value has occurred since the start of the measurement.

  In addition, it is possible to search by the molding time in one molding, and by specifying the molding time, it is possible to read out the measurement data that exceeds the specification, and conversely, the molding time is insufficient (the molding time is short). Under) The measurement data can also be read, and it is possible to easily determine whether the product is good or defective. Furthermore, the molding time of each cycle can be totaled and used for calculating the operation rate of the machine. Further, the result can be displayed as a form or a graph on a personal computer.

  In the above description, the search data is stored in the RAM 24. However, the data is stored in the data recording and storage device 25 for each sampling. In the case of the search data, a flag is set and the search is performed. In such a case, the search may be performed only on the data for which the flag is set.

  Alternatively, a value that is a defective product may be set in advance, and when the measured value exceeds the set value, an alarm may be issued and the molding operation may be stopped. Such a value can be used as search data itself, for example, the maximum value of the pressing force. Further, the root-mean-square error of a series of sample values is calculated for each processing, and the result is calculated from a predetermined range. When it deviates, it can be determined that a defective product has occurred. That is, the entire waveform can be compared. Further, in addition to taking measures after the occurrence of a defective product, when a tendency of occurrence is predicted in advance, the danger may be notified by an alarm or the like.

  If the cause of the product or molding process failure is a machine-adjustable value, such as a decrease or abnormal rise in hydraulic pressure, deviation from a predetermined voltage range, or a change in the heating temperature by a heater, these factors are set in advance. A signal may be fed back from the data collection device 2 so as to adjust the value to a correct range. In this case, it is a device in which the data collection device and the controller are combined, rather than a simple data collection device. The monitor device in the present invention includes such a united device.

  The criteria for discriminating the defective product or the defective molding process are determined in advance by checking the dimensions of many products and analyzing the molding data. However, even when molding for the first time, provisional reference values that are stricter than normal reference values are determined in advance, dimensions are measured when a certain amount of product is obtained, and the reference values are changed based on the results. Alternatively, a reference value can be determined in real time.

  An alarm can be output based on such a standard, or a control signal can be sent to the machine side.However, a standard product without an alarm output or machine control output is used as a standard product. It may be added to the standard product as an option or a quasi-option. There are various ways to set an alarm, and the above-described embodiment is merely an example. There are types of timing alone, such as output in real time or output at the end of one cycle, and the range of alarm setting may differ depending on the molding content of the target. Generally, (1) the lower limit to the upper limit are set, and a value is issued when the value exceeds the range at a certain point such as the maximum value. (2) The specific value is simply set and exceeded during the cycle. (3) In a certain section (from the entire range to one point) in the cycle, a comparison is made with a predetermined waveform, the comparison between waveforms and the comparison with an arbitrarily set numerical sequence are performed. Therefore, when a deviation exceeding a certain value occurs, (4) a differential operation (energy such as acceleration, pressure rise within a certain time, etc.) is calculated in a cycle, and as a result, a difference exceeding a certain value is obtained. (5) Output when the result of calculation of data of two or more waveforms (calculation of a plurality of data at the same time) does not fall within a predetermined range.

  As for the output format, (1) a signal is sent to the machine side in consideration of a timer element and a calculation element in relation to the alarm output, and (2) timing generation of various output signals is performed on the WEB screen. There is a signal output based on the slide detection signal, and a signal output for operating an accessory of the machine in general.

  In the above embodiment, a hydraulic press is adopted as an example of the mass production machine, but a mechanical press may be used. Further, an injection molding machine or the like may be used. In the case of an injection molding machine, the data for drawing a waveform can include the pressure of the mold clamping device, the position of the mold clamping device, the temperature of the mold, the displacement of the mold, the injection pressure, and the like. The search data includes the maximum pressing force of the mold clamping device, the maximum displacement of the mold clamping device, the maximum temperature of the mold, the maximum displacement of the mold, and the maximum or minimum value of the injection pressure.

  Further, in the above embodiment, the data collection device is a stand-alone type. However, a data collection device integrated with a machine or a personal computer is also included in the production management monitor of the present invention. In the above-described embodiment, all data is stored in the data recording and storage device 25. However, not all of the data but only the main part may be stored. As a result, the amount of data to be stored in the storage means can be reduced, and long-term molding data can be stored. In addition, it is also possible to create waveform data based on the data of such a main part, and to display an image based on the created waveform. In such a case, it is preferable to determine in advance by experiment or the like what data is effective as the main part for discrimination for each product or mold.

  In FIG. 2, the digital signal emitted from the position sensor 10 is input to the I / O interface 20, but in the case of an analog signal, it is input to the A / D converter 21. Input signals from various sensors are also input to the I / O interface 20 in the case of digital signals.

  In the description of FIG. 4, it is described that the forming process is started by the forming start signal and the measurement is started at the same time, but the start of the measurement is started by a measurement start signal that is separate from the operation start of the machine. Is also good. Similarly, the measurement can be ended by turning off the measurement end signal or the measurement start signal. It may be performed at a different timing. That is, the machine is operated in a safe one-step operation (operation mode in which the ram descends and rises once, stops at the top dead center, and starts the next operation via an interlock that confirms a predetermined safety). One-step operation (operation mode in which the molding start button is pressed and the machine does not stop at the top dead center and enters the next descent operation) or continuous operation (when the operation start button is pressed once and then released) Since the operation is performed in various operation modes such as an operation mode in which continuous operation is continued), it is more convenient to determine the timing of measurement start and measurement end separately from the operation start button.

  For example, based on a signal from a position sensor (reference numeral 10 in FIG. 2) for detecting the position of a ram (slider) provided in the processing apparatus 1, measurement is started when the ram reaches a predetermined position, and another measurement is started. Each of the data collection devices (the personal computer) can be set so that the measurement is terminated when it reaches a predetermined position. In this case, if there is no other use, the “molding start button” in FIG. 2 can be omitted. When the measurement start or measurement end time is set based on such ram position information, it can be easily set or changed on the personal computer side.

  In other words, the molding start signal in the present invention takes into account the operation mode (measurement target mode) of the press operation, such as one safety step, one continuous step, and one continuous step, and a signal when the start signal is actually input. In some cases, regardless of the operation mode, the position sensor detects and determines that the slide has actually started to descend. Further, both can be set together. If both can be set, for example, an appropriate signal may be selected according to the operation mode.

FIG. 1 is an overall system configuration diagram according to an embodiment of the present invention. It is a block diagram of a hardware function of a data collection device in an embodiment of the invention. It is a block diagram of the software function which shows one Embodiment of the data collection device in embodiment of this invention. 6 is a flowchart in the case of performing control based on an alarm value according to the present invention. FIG. 4 is a block diagram illustrating software functions of a personal computer on the search side according to the embodiment of the present invention. 5 is a flowchart in the case of collecting and storing various data during molding in the embodiment of the present invention. 5 is a flowchart in the case of collecting and storing various data during molding in the embodiment of the present invention. FIG. 5 is an explanatory diagram showing a storage state when search data and all of them are stored in the embodiment of the present invention. Serial No. in the embodiment of the present invention. Is a flowchart in the case of automatically assigning. Serial No. in the embodiment of the present invention. 11 is a flowchart showing another embodiment in which is automatically given. It is a flowchart at the time of calculating | requiring the pressurization maximum value in embodiment of this invention. It is a flowchart in the case of calculating | requiring the pressurization minimum value in embodiment of this invention. 6 is a flowchart when a search is performed from the personal computer side according to the embodiment of the present invention. 6 is a flowchart when a search is performed from the personal computer side according to the embodiment of the present invention. 6 is a flowchart when a search is performed from the personal computer side according to the embodiment of the present invention. It is explanatory drawing which shows the relationship between the pressurization maximum value and the maximum value time in embodiment of this invention.

Explanation of reference numerals

DESCRIPTION OF SYMBOLS 1 Processing device 2 Data collection device 3 Hub 4 Personal computer 5 Modem 6 Communication line 10 Position sensor 11 Pressure sensor 12 Temperature sensor 13 Die displacement sensor 14 Molding start button 15 Limit switch 20 I / O interface 20
21 A / D conversion 22 CPU
23 ROM
24 RAM
25 Data recording and storage device (hard disk)
26 Communication Interface 27 Alarm 29 Alarm Value Comparison Unit
Reference Signs List 30 Physical unit value conversion unit 31 Data value comparison unit 32 Molding data file creation unit 33 Ram speed calculation unit 34 Counter unit 35 Date / time / clock unit 36 Search unit 37 Waveform data reading unit 38 Molding time calculation unit 39 Search file creation unit 40 Control unit 41 Search control unit 42 Data transfer control unit 43 Waveform display control unit 44 Data format conversion unit 45 Operation input unit 46 RAM
47 display unit 48 storage unit 49 communication interface 50 alarm setting unit 51 alarm setting unit

Claims (8)

A device used for production control of machines that mass-produce the same product,
Means for detecting a change in the state of the machine when the machine manufactures one product as a series of numerical values;
Means for creating a specific numerical value as search data from the numerical value sequence,
Means for storing the obtained search data in association with a code identifying a manufactured product or a molding process;
Search means for searching the search data for one that matches the input specific condition;
An output device for outputting a product or a molding process code corresponding to the data retrieved by the retrieval device.   2. The production management monitor device according to claim 1, further comprising a second storage unit that stores all or a main part of the series of numerical values in association with a product or a molding process code.   3. The production management monitor device according to claim 2, wherein said second storage means is a randomly accessible storage device having a storage capacity of 100 megabytes or more.   4. The production management monitor device according to claim 3, wherein the storage device is a hard disk.   3. The production management monitor device according to claim 1, further comprising a display unit for displaying, as a waveform image, detection data corresponding to a specified product among codes of the product or the molding process output by the output unit.   The machine is a press machine, and the state includes a ram pressing force, a ram position, a ram guide portion temperature, a mold displacement amount, a mold temperature, a die cushion generating ability, a knockout generating ability, and a frame. 3. The production management monitoring device according to claim 1, wherein the monitor is in one or more states selected from the group consisting of a displacement amount, a die cushion position, a knockout position, a lubricating oil temperature, and a main motor current value.   The series of detected numerical sequences is compared with a numerical sequence that is a criterion for the acceptance of a product or a molding process. 3. The monitor device for production management according to claim 1, further comprising means for performing the operation.   3. The production management monitor device according to claim 1, wherein a device for inputting the search condition and a search unit are connected by communication so that a search can be performed from a remote place.

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